Universal box build

ABSTRACT

A method and apparatus for generating consumer electronics using a Universal Box Build (UBB) are disclosed herein. The method may include entering specifications of a product comprised of a printed circuit board (PCB), additional components (such as Central Processing Units (CPUs), memory modules, and heatsinks) into a chassis module, inserting a set of required components in the UBB, and generating the PCB assembly based on the entered specifications, wherein a robot is operatively connected to the interface module to automatically generate a product assembly.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.14/666,470 filed on Mar. 24, 2015, which is incorporated by reference asif fully set forth.

FIELD OF INVENTION

This application is in the field of electronics.

BACKGROUND

In the market, there are various consumer electronics devices withdifferent brands. Each brand may have a different number of componentsto assemble a server or a different way of arranging similar components.Each server may have different specifications as well. Most devices arecreated manually with the help of tools. Some devices are created usingautomated systems, but these are used for a specific consumer productonly.

Currently there is no universally generic approach to the currentautomated systems. There exists is a need for a universal system thatincludes the tooling required to program positions, datum, and fiducialson consumer electronic devices and assemble them with a low changeovertime between specifications.

SUMMARY

A method and apparatus for generating consumer electronics using aUniversal Box Build (UBB) herein. The method may include enteringspecifications of a product comprised of a printed circuit board (PCB),additional components, such as Central Processing Units (CPUs), memorymodules, and heatsinks into a chassis, inserting a set of componentsrequired into the UBB, and generating the PCB based assembly on theentered specifications, wherein a robot is operatively connected to theinterface module to automatically generate the product assembly.

BRIEF DESCRIPTION OF THE DRAWING(S)

FIG. 1 is an example of a Universal Box Build (UBB);

FIG. 2 is an example of a front view and a side view of the UBB;

FIG. 3 is a top view of the UBB;

FIG. 4 is an example of a heatsink gripper;

FIG. 5 is an example of an inertia resistant screw bit;

FIG. 6 is an example of a kitting tray;

FIG. 7 is an example of a memory modules gripper;

FIG. 8 is an example of an ODM MB gripper;

FIG. 9 is an example of a CPU gripper;

FIG. 10 is an example of a MB gripper;

FIG. 11 is an example of a CPU cover gripper; and

FIG. 12 is an example of a CPU socket latch handling tool.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

It is to be understood that the figures and descriptions of embodimentsof a Universal Box Build (UBB) have been simplified to illustrateelements that are relevant for a clear understanding, while eliminating,for the purpose of clarity, many other elements found in typical vehiclesystems. Those of ordinary skill in the art may recognize that otherelements and/or steps are desirable and/or required in implementing thepresent invention. However, because such elements and steps are wellknown in the art, and because they do not facilitate a betterunderstanding of the present invention, a discussion of such elementsand steps is not provided herein.

The non-limiting embodiments described herein are with respect to systemand method of activating or triggering predetermined functions forvehicle electromechanical systems based on image recognition and radiofrequency systems. Other electronic devices, modules and applicationsmay also be used in view of these teachings without deviating from thespirit or scope as described herein. The UBB may be modified for avariety of applications and uses while remaining within the spirit andscope of the claims. The embodiments and variations described herein,and/or shown in the drawings, are presented by way of example only andare not limiting as to the scope and spirit. The descriptions herein maybe applicable to all embodiments of the UBB although it may be describedwith respect to a particular embodiment.

A Universal Box Build (UBB) may be used to create consumer electronicdevices for multiple brands including tools to program positions, datum,and fiducials and assemble the devices with low changeover timespecifications. The UBB may have full traceability and data recordingusing various sensors, (for example, torque on screws, force appliedwhen placing the components, deflection on a printed circuit board (PCB)main board, force when a memory module is inserted, a parts presenceindicator, and a machine vision to record the incoming components state)while also using the their characteristics for handling to address thevariability of off the shelve parts. Recorded data and images forquality validation and traceability may be transmitted to aManufacturing Execution System (MES) making the cell Internet of Things(IoT) ready.

The end effectors and work flow of the cell may be designed toaccommodate several standards of components with the universal functiontrain of thought from the group up. Adaptability to several standardcomponents has been accomplished with adjustable gripping tools. Precisepositioning is done with respect to fixed fiducials from themanufacturing of the components and characteristics. For traceability,all of the measurements and quality assurance data may be connected tothe MES system, making the cell IOT ready.

FIG. 1 is an example of a Universal Box Build (UBB). The UBB 100includes a box 101, a rolling cart 102, a kitting tray 103, a robot 104,a tool changer 105, a robotized screw tool 106, a gate 107, an end ofarm tool box 108, and a human interface module 109. The tool box 108 mayinclude a heatsink gripper, an inertia resistant screw bit, a memorymodules gripper, an ODM MB gripper, a CPU gripper, a MB gripper, a CPUcover gripper, and a CPU socket latch. Each one of these tools mayattach to the tool changer to add a specific piece, for example aheatsink, a CPU, a memory module, and the like, to the PCB. Thisinterchangeability may allow the UBB to perform the necessary functionsof assembling to the PCB after a user input of the requiredspecifications.

The user may input the specifications of the PCB into the human moduleinterface. The computer may then respond by bringing in the productchassis from the rolling cart 102 into the UBB 101. The UBB may thenassemble onto the PCB based on the specifications inputted by the userthe quantities of components from the kitting tray. The robot 104 is arobotic arm that engages the tool changer 105 to pick up the necessarytool from the tool box 108. Once the robot 104 has the necessary tool,it moves to the kitting tray 103 to obtain the PCB that will beassembled to the chassis. The robot 104 picks up the necessary piece andplaces it on the PCB. The screw tool 106 then attaches the necessarypiece(s) to the PCB. Once all of the pieces are attached to the PCBbased on the inputted specifications, the rolling cart 102 slides outfrom the UBB to allow the user to obtain the finished product.

FIGS. 2 and 3 show the UBB from different angles. FIG. 2 is an exampleof a front view 200(a) and a side view 200(b) of the UBB. Figure. FIG. 3is a top view 300 of the UBB.

FIG. 4 is an example of the heatsink gripper. The heatsink gripper maybe used to grab, install, and hold on position a generic heat sink. Theheatsink gripper in FIG. 4 is shown from three angles, a top view400(a), a side view 400(b), and a rear view 400(c). The side view 400(b)illustrates the various elements of the heatsink gripper. The heatsinkgripper may include a tool changer adaptor 401, a heatsink gripperfinger 402, a prox mount 404, a prox flag 405, a QC-20 tool 406, aconnector 407, a jaw gripper 408, an auto switch 409, an elbow fitting410, a prox switch 411, a cordset 412, and a sock cap screw 413. Therear view 400(c) of the heatsink gripper illustrates the heatsinksupport 403.

FIG. 5 is an example of an inertia resistant screw bit. The inertiaresistant screw bit, used on fast moving tools, may help with inertiaissues when moving slim screw bits at full speed on a robot to have aprecise tip location. The inertia resistant screw bit in FIG. 5 is shownfrom several angles: a rear angle 500(a), a top view 500(b), and a sideview 500(c). The side view 500(c) of the inertia resistant screw bit,when cut along the A′ line 510, results in the image shown in 500(d).The inertia resistant screw bit may include a Phillips bit 501, abushing 502, a screw centering sleeve 503, a dowel pin 504, and acylinder magnet 505.

FIG. 6 is an example of a kitting tray. The kitting tray 604 may includereinforcement (underneath) 601, PCB supports 602, memory module support603, memory module slots 605, PCB reference corner 606, an operatorhandle 607, position lockdown holes 608, CPU holders 609, and heatsinkholders 610. The kitting tray 604 may be used to hold the components andaid in controlling the pick-up of these components through preciselocation or machine vision location. The kitting tray 604 may includeseveral spaces to accommodate several families of server components. Thespaces may be filled with the required components. The components may behandled through a recipe system on the human module interface. Thekitting tray 604 has a poka-yoke, or mistake-proof, design to avoid anyerrors when placing components.

FIG. 7 is an example of a memory modules gripper. The memory modulesgripper may be used to pick up and insert RAM memory modules whilesafely addressing the quality and avoiding any damage to the module. Thememory modules gripper in FIG. 7 is shown from two angles, a top view700(a) and a side view 700(b). The side view 700(b) illustrates thevarious elements of the memory modules gripper. The memory modulesgripper may include a tool changer adaptor 701, a finger adaptor 702, agripper finger 703, a module block 704, a QC-20 tool 705, a connector706, a jaw gripper 707, an auto switch 708, and an elbow fitting 709.

FIG. 8 is an example of an ODM MB gripper. The ODM MB gripper in FIG. 8is shown from three angles, a top view 800(a), a side view 800(b), and aplanar view 800(c). The side view 800(b) illustrates the variouselements of the ODM MB gripper. The ODM MB gripper may include a toolchanger adaptor 801, a MB gripper finger 802, a MB gripper pin 803, aQC-20 tool 804, a connector 805, a jaw gripper 806, an auto switch 807,and an elbow fitting 808.

FIG. 9 is an example of a CPU gripper. The CPU gripper in FIG. 9 isshown from three angles, a top view 900(a), a side view 900(b), and abottom view 900(c). The bottom view 900(c) illustrates the variouselements of the CPU gripper. The CPU gripper may include a tool changeradaptor 901, a spring pin block 902, a QC-20 tool 903, a connector 904,a first contact probe 905, a first receptacle 906, a second contactprobe 907, a second receptacle 908, a vacuum chip 909, and an elbowfitting 910.

FIG. 10 is an example of a MB gripper. The MB gripper in FIG. 10 isshown from three angles, a top view 1000(a), a side view 1000(b), and arear view 1000(c). The rear view 1000(c) illustrates the variouselements of the citrix MB gripper. The citrix MB gripper may include atool changer adaptor 1001, a citrix MB gripper finger 1002, a MB supportfinger 1003, a QC-20 tool 1004, a connector 1005, a jaw gripper 1006, anauto switch 1007, and an elbow fitting 1008.

FIG. 11 is an example of a CPU cover gripper. The CPU cover gripper inFIG. 11 is shown from three angles, a top view 1100(a), a side view1100(b), and a rear view 1100(c). The side view 1100(b) illustrates thevarious elements of the CPU cover gripper. The CPU cover gripper mayinclude a tool changer adaptor 1101, a CPU cover gripper arm 1102, afinger holder 1103, a cover gripper finger 1104, a QC-20 tool 1105, aconnector 1106, a jaw gripper 1107, an auto switch 1108, and an elbowfitting 1109.

FIG. 12 is an example of a CPU socket latch handling tool. The CPUsocket latch handling tool in FIG. 12 is shown from three angles, a topview 1200(a), a front view 1200(b), and a side view 1200(c). The sideview 1200(c) illustrates the various elements of the CPU socket latch.The CPU socket latch may include a tool changer adaptor 1201, a latchtool adaptor 1202, a CPU latch tool 1203, a QC-20 tool 1204, and aconnector 1205.

As described herein, the methods described herein are not limited to anyparticular element(s) that perform(s) any particular function(s) andsome steps of the methods presented need not necessarily occur in theorder shown. For example, in some cases two or more method steps mayoccur in a different order or simultaneously. In addition, some steps ofthe described methods may be optional (even if not explicitly stated tobe optional) and, therefore, may be omitted. These and other variationsof the methods disclosed herein will be readily apparent, especially inview of the description of the systems described herein, and areconsidered to be within the full scope of the invention.

Although features and elements are described above in particularcombinations, each feature or element can be used alone without theother features and elements or in various combinations with or withoutother features and elements.

What is claimed is:
 1. A method for forming consumer electronics using aUniversal Box Build (UBB), the method comprising: inserting into the UBBa set of printed circuit board (PCB) components; inserting into the UBBa PCB; entering specifications of a product recipe using an interfacemodule, wherein the product recipe includes instructions to assemble aPCB product assembly; and forming the PCB product assembly based on theentered specifications of the product recipe using the set of PCBcomponents, wherein the set of PCB components are used to populate thePCB, and a robot is operatively connected to the interface module toautomatically form the PCB product assembly.
 2. The method of claim 1,wherein entering specifications of a product recipe using the interfacemodule are input by a user.
 3. The method of claim 1, wherein insertingthe PCB into the UBB is included in the instructions of the productrecipe.
 4. The method of claim 1, wherein the UBB further comprises akitting tray, and the kitting tray comprises the set of PCB componentsused to populate the PCB product assembly.
 5. The method of claim 4,wherein the set of PCB components includes at least one of a heatsink, aCPU, a CPU cover, and a memory module.
 6. The method of claim 1, whereinthe UBB further comprises a tool box having a plurality of tools,wherein each tool of the plurality of tools is configured to add atleast a specific component of the set of PCB components to the PCB. 7.The method of claim 6, wherein the plurality of tools includes at leastone of a heatsink gripper, an inertia resistant screw bit, a memorymodules gripper, a central processing unit (CPU) gripper, a mother board(MB) gripper, an original design manufacturer (ODM) MB gripper, a citrixMB gripper, a CPU cover gripper, and a CPU socket latch.
 8. The methodof claim 6, wherein the robot comprises a robotic arm configured to pickup the plurality of tools.
 9. The method of claim 8, wherein the UBBfurther comprises a tool changer configured to engage with the roboticarm and facilitate attachment of the plurality of tools to the roboticarm.
 10. The method of claim 8, wherein forming the PCB product assemblyfurther includes picking up the plurality of tools by the robot arm, onetool at a time based on the entered specifications of the productrecipe.
 11. The method of claim 10, wherein forming the PCB productassembly further includes moving of the robotic arm to the kitting trayto obtain a component of the set of PCB components corresponding to atool of the plurality of tools, and placing the component on the PCBbased on the entered specifications of the product recipe.
 12. Themethod of claim 1, wherein forming the PCB product assembly furtherincludes attaching the set of PCB components to the PCB using a screwtool based on the entered specifications of the product recipe.
 13. Themethod of claim 1, wherein the PCB is coupled with a product chassis,and the product chassis and the PCB are located on a top surface of arolling cart.
 14. The method of claim 13, wherein enteringspecifications of a product recipe using the interface module furtherincludes instructions to insert the rolling cart into the UBB prior toforming the PCB product assembly.
 15. The method of claim 13, whereinupon formation of the PCB product assembly, the rolling cart comprisingthe PCB product assembly slides out from the UBB.
 16. The method ofclaim 1, further comprising data recording ability using at least asensor of a plurality of sensors.
 17. The method of claim 17, whereinthe plurality of sensors is at least one of a sensor of torque appliedon screws, a sensor of force applied when placing a component of the setof PCB components onto the PCB, a sensor to sense deflection of the PCB,a sensor to indicate presence of a part, and a sensor to sense incomingof each component of the set of PCB components.
 18. The method of claim17, wherein recorded data is transmitted to a manufacturing executionsystem.